Kalmar DCE80-100E Manuals

Manuals and User Guides for Kalmar DCE80-100E. We have 1 Kalmar DCE80-100E manual available for free PDF download: Technical Handbook

Kalmar DCE80-100E Technical Handbook

Kalmar DCE80-100E Technical Handbook (317 pages)

Brand: Kalmar | Category: Trucks | Size: 18.55 MB

Table of Contents

Group 00

3
- Table of Contents
  3
- Safety Regulations
  
  4
- Group 00
  
  4
- General
  
  8
  - Applications
    8
  - Design
    8
  - Component Units
    10
  - Supplementary Books
    11
  - Replacement System - Spare Parts
    11
  - Tools
    11
  - Tightening Torques
    12
  - System of Units
    14
Group 10 Chassis and Cab

15
- Specifications
  17
  - Chassis
    17
    
    Description
    18
  - Operator's Cab
    18
    
    Description
    19
    
    Steering Column
    21
    
    Changing the Fresh Air Filter
    22
    
    Service
    22
    
    Check and Lubrication of Brake Pedal
    23
    
    Windscreen Wipers
    24
  - Air Conditioning Unit
    25
    
    Description
    25
    
    Checking the Air Conditioning Unit
    28
    
    Service
    28
Group 20 Electrical System

31
- Specifications
  
  32
- Group 20
  
  32
- Electrical System
  
  33
  - Description
    33
    
    Bulbs
    37
    
    Checking the Electrolyte Level of the Batteries
    37
    
    Relays
    39
    
    Sockets in Electrical Central
    40
    
    Electrical Diagram Explanations
    41
  - List of Circuit Diagrams
    42
Group 30

113
- Volvo TWD731VE
  
  115
  - Engine TWD731VE
    117
    
    Description
    117
    
    Cooling System
    118
    
    Fuel System
    120
    
    Lubrication System
    124
    
    Combustion Air System
    125
    
    Coolant Quality
    127
    
    Draining the Water from the Fuel Tank
    127
    
    Lubrication Oil Quality
    127
    
    Service
    127
    
    Changing the Oil and Oil Filter
    128
    
    Checking V-Belt Tension
    128
    
    Changing the Fuel Filter
    129
    
    Preventive Maintenance on Turbo-Charger
    130
- Volvo TAD720VE
  
  131
  - Description
    133
    
    Overview
    133
    
    Cooling System
    135
    
    Fuel System
    137
    
    Lubrication System
    139
  - Service
    143
    
    Coolant Quality
    143
    
    Draining the Water from the Fuel Tank
    143
    
    Lubrication Oil Quality
    143
    
    Changing the Oil and Oil Filter
    144
    
    Checking V-Belt Tension
    144
    
    Checking and Adjusting the Valve Clearances.32
    145
    
    Changing the Fuel Filter
    146
    
    Preventive Maintenance on Turbo-Charger
    147
  - Group 30
    147
  - Description
    148
    
    Overview
    150
    
    Cooling System
    152
    
    Fuel System
    153
    
    Lubrication System
    154
  - Engine QSB 5.9
    148
  - Service
    157
    
    Coolant Quality
    157
    
    Draining the Water from the Fuel Tank
    157
    
    Lubrication Oil Quality
    157
    
    Changing the Oil and Oil Filter
    158
    
    Changing the Fuel Filter
    160
    
    Preventive Maintenance on Turbo-Charger
    161
Group 40 Transmission, Drive Axle, Brakes

163
- Specification
  165
  - Transmission
    165
    
    Description
    165
    
    Gearbox
    165
    
    Torque Converter
    165
    
    Oil Circuit
    168
    
    Changing Gearbox Oil and Filter
    169
    
    Oil Level Check
    169
    
    Service
    169
  - Drive Axle
    171
    
    Description
    171
    
    The Differential
    171
    
    Hub Reduction
    172
    
    Service Brake
    173
    
    Parking Brake System
    174
    
    Releasing the Parking Brake by Mechanical Means
    174
    
    Changing the Drive-Axle Oil
    175
    
    Service
    175
    
    Installation of Disc Brake
    176
    
    Installing the Brake on the Axle
    178
    
    Dismantling the Planet Gear
    182
Group 60

183
- Group 60
  184
- Steering Axle
  
  185
- Specifications
  
  185
  - Description
    185
  - Steering Axle
    185
  - Service
    186
    
    Replacement of Steered Wheel Bearings
    186
    
    Replacement of Steering Cylinder
    186
    
    Replacement of Knuckle Pin Bearings
    188
    
    Inspection of Dismountable Rims
    190
    
    Safety Test When Changing Tyres
    192
Group 70

193
- Group 70
  194
- Specifications
  195
  - Hydraulic System
    195
  - Main Hydraulics
    195
    
    Description
    195
    
    General Survey
    195
    
    Standad Hydraulic System
    195
    
    - Hydraulic-Servo
    199
    
    Hydraulic System with Separate Side-Lift Hydraulics
    199
    
    Lifting
    203
    
    Lowering Brake Valve
    204
    
    Tilting
    205
    
    Attachment Supply
    206
    
    Breather Filter
    207
    
    Changing the Hydraulic Fluid
    207
    
    Checking the Hydraulic Hoses
    207
    
    Mounting of Fittings on Hydraulic Hoses
    207
    
    Service
    207
  - Steering System Description
    211
    
    Steering Valve
    212
  - Brake System
    214
    
    Brake System WDB-System
    214
    
    Description
    214
    
    Oil Cooler
    216
    
    Checking the Brake System
    217
    
    Service
    217
  - Parking Brake
    218
    
    Description
    218
  - Hydraulic Pumps
    221
    
    Description
    221
  - Accumulator
    224
    
    Description
    224
  - High Pressure Filter
    225
    
    Description, Service
    225
  - Main Valve
    226
    
    Description
    226
    
    Service
    230
Table of Contents

245
- Clean Hydraulics
  247
- Hydraulic Cylinders
  247
  - Service
    247
- Measures to Prevent Pollution of the Hydraulic System
  248
- Fault Finding for Leakage
  250
- The Function and Removal of Seals
  251
  - Piston Rod Seals
    251
  - Support Ring and O Ring
    253
  - Wiper
    254
  - Single Action V Type Piston Seals with Support Ring
    255
  - Double Action Piston Seals
    256
- Repairing the Piston Rod Surface
  256
- Lubrication
  257
- Dismantling the Steering Cylinder
  258
Group 80 Lifting Mast Carriage and Side Lift Attachment

261
- Specifications
  262
  - Description
    263
  - Inspection of Lifting Chains
    267
  - Inspection of the Lifting Mast
    267
  - Service
    267
  - Dismantling the Carriage
    268
  - Adjusting the Support Wheels
    269
  - Replacing the Support Wheels
    269
  - Lubrication of Sliding Surfaces and Plates
    270
  - Checking Tilt Cylinders
    271
  - Inserting Shims for Sliding Plates
    271
  - Stretching of Hoses
    271
  - Tilt Cylinder Mounting
    271
- Lift Mast and Carriage
  
  263
  - Sidelift Attachment
    273
    
    Description
    273
    
    Service
    275
    
    Sidelift with Twist-Locks
    275
    
    Sidelift with Hook-Coupling
    276
    
    Inductive Sensors
    277
    
    Control of Lifting Hooks
    278
    
    Control of Twist-Locks
    278
- Sidelift with Hooks, C-Type
  
  278
  - Service
    278
    
    Alignment Control
    286
    
    Inductive Sensors
    287
    
    Sensor for Interrupting of Lowering
    287
    
    Control of Lifting Hooks
    288
    
    Block Diagram
    291
    
    Hydraulic System A46141.0100
    292
  - Periodic Supervision
    305
    
    General Survey
    305
    
    General Survey Chart
    305
    
    Daily Supervision
    312
    
    Every 500 Hours
    313
    
    Every 1000 Hours
    315
    
    Oil and Lubricant Recommendations
    316

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